Sprinkler with internal compartments

ABSTRACT

A sprinkler includes a compartment that surrounds its riser portion in an offset or asymmetrical configuration. More specifically, the distance of the compartments walls from those of the riser vary (i.e., increase or decrease) at different locations surrounding the riser. Put another way, the riser is closer to one side of the compartment than other sides of the compartment. This non-concentric configuration allows larger components to fit inside the compartment than would otherwise fit if the riser was symmetrically surrounded by the compartment.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/982,863 filed May 17, 2018 entitled Sprinkler With InternalCompartments, which is a continuation of U.S. patent application Ser.No. 15/352,422 filed Nov. 15, 2016 (now U.S. Pat. No. 9,987,649 issuedJun. 5, 2018), which is a continuation of U.S. patent application Ser.No. 14/280,113, filed May 16, 2014 entitled Sprinkler with InternalCompartments (now U.S. Pat. No. 9,539,602 issued Jan. 10, 2017), whichclaims benefit of U.S. Provisional Application Ser. No. 61/824,212 filedMay 16, 2013 entitled Sprinkler with Internal Compartments, all of whichare hereby incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

Sprinkler systems for turf irrigation are well known. Typical systemsinclude a plurality of valves and sprinkler heads in fluid communicationwith a water source, and a centralized controller connected to the watervalves. At appropriate times the controller opens the normally closedvalves to allow water to flow from the water source to the sprinklerheads. Water then issues from the sprinkler heads in predeterminedfashion.

There are many different types of sprinkler heads, includingabove-the-ground heads and “pop-up” heads. Pop-up sprinklers, thoughgenerally more complicated and expensive than other types of sprinklers,are thought to be superior. There are several reasons for this. Forexample, a pop-up sprinkler's nozzle opening is typically covered whenthe sprinkler is not in use and is therefore less likely to be partiallyor completely plugged by debris or insects. Also, when not being used, apop-up sprinkler is entirely below the surface and out of the way.

The typical pop-up sprinkler head includes a stationary body and a“riser” which extends vertically upward, or “pops up,” when water isallowed to flow to the sprinkler. The riser is in the nature of a hollowtube which supports a nozzle at its upper end. When the normally-closedvalve associated with a sprinkler opens to allow water to flow to thesprinkler, two things happen: (i) water pressure pushes against theriser to move it from its retracted to its fully extended position, and(ii) water flows axially upward through the riser, and the nozzlereceives the axial flow from the riser and turns it radially to create aradial stream. A spring or other type of resilient element is interposedbetween the body and the riser to continuously urge the riser toward itsretracted, subsurface, position, so that when water pressure is removedthe riser assembly will immediately return to its retracted position.

The riser assembly of a pop-up or above-the-ground sprinkler head canremain rotationally stationary or can include a portion that rotates incontinuous or oscillatory fashion to water a circular or partly circulararea, respectively. More specifically, the riser of the typical rotarysprinkler includes a first portion (e.g. the riser), which does notrotate, and a second portion, (e.g. the nozzle assembly) which rotatesrelative to the first (non-rotating) portion.

The rotating portion of a rotary sprinkler riser typically carries anozzle at its uppermost end. The nozzle throws at least one water streamoutwardly to one side of the nozzle assembly. As the nozzle assemblyrotates, the water stream travels or sweeps over the ground.

The non-rotating portion of a rotary sprinkler riser assembly typicallyincludes a drive mechanism for rotating the nozzle. The drive mechanismgenerally includes a turbine and a transmission. The turbine is usuallymade with a series of angular vanes on a central rotating shaft that isactuated by a flow of fluid subject to pressure. The transmissionconsists of a reduction gear train that converts rotation of the turbineto rotation of the nozzle assembly at a speed slower than the speed ofrotation of the turbine.

During use, as the initial inrush and pressurization of water enters theriser, it strikes against the vanes of the turbine causing rotation ofthe turbine and, in particular, the turbine shaft. Rotation of theturbine shaft, which extends into the drive housing, drives thereduction gear train that causes rotation of an output shaft located atthe other end of the drive housing. Because the output shaft is attachedto the nozzle assembly, the nozzle assembly is thereby rotated, but at areduced speed that is determined by the amount of the reduction providedby the reduction gear train.

Another feature of many prior art sprinklers is the use of electricallyactuated pilot valves which connect in-line with the irrigation watersupply and a sprinkler, allowing the water flow to an individualsprinkler to be turned on or off, preferably from a distant centralcontrol system. Typically, these pilot valves are located partially oreven completely outside the sprinkler body. Thus, when the pilot valveneeds adjustment or replacement, a user must shut off the water supplyleading to the pilot valve, dig around the sprinkler to find the pilotvalve, replace the pilot valve, rebury it, then turn the water supplyback on. Since the main water supply must be shut off, other sprinklerswill not function during this time consuming repair and may interruptpreprogrammed watering cycles.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is directed to a sprinklerhaving a compartment that surrounds its riser portion in an offset orasymmetrical configuration. More specifically, the distance of thecompartments walls from those of the riser vary (i.e., increase ordecrease) at different locations surrounding the riser. Put another way,the riser is closer to one side of the compartment than other sides ofthe compartment. This non-concentric configuration allows largercomponents to fit inside the compartment than would fit if the riser wassymmetrically surrounded by the same size compartment.

In another aspect of the present invention, the compartment furthercomprises a check valve and a pressure receptacle that are located inproximity to each other to allow connection to each by a pilot valve.The check valve and pressure receptacle are also preferably shaped andoriented to allow the pilot valve to be upwardly removed from thecompartment of the sprinkler. Preferably, the pressure receptacle ismechanically fastened over an injection-molded aperture into the risercavity.

In another aspect of the present invention, the sprinkler includes ametal communication tube that is injection molded into a fin or ribextending away from a lower portion of the riser housing. Preferably,the communication tube is partially exposed near its lower end to helpaccommodate for warping or shrinking that is sometimes inherent in theinjection molding process.

In another aspect of the present invention, the sprinkler cavity mayinclude a wireless communication module. This module may be configuredto communicate with a nearby sensor, such as a soil moisture sensor andrelay data back to a central controller. This module may also beconfigured as a node in a mesh network.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects, features and advantages of which embodiments ofthe invention are capable of will be apparent and elucidated from thefollowing description of embodiments of the present invention, referencebeing made to the accompanying drawings, in which:

FIG. 1 illustrates a perspective view of a top accessible sprinkleraccording to the present invention.

FIG. 2 illustrates a perspective view of a sprinkler compartment housingaccording to the present invention.

FIG. 3 illustrates a bottom perspective view of the sprinkler of FIG. 1.

FIGS. 4 and 5 illustrate a top view of the sprinkler compartmentaccording to the present invention.

FIG. 6 illustrates a side cross sectional view of the sprinkler of FIG.1.

FIG. 7 illustrates a magnified view of the check valve of FIG. 6.

FIG. 8 illustrates a side cross sectional view of the sprinkler of FIG.1.

FIG. 9 illustrates a magnified view of a pilot valve connection port ofFIG. 8.

FIG. 10 illustrates a side cross sectional view of the sprinkler of FIG.1.

FIGS. 11 and 12 illustrates magnified views of portions of FIG. 10.

FIGS. 13 and 14 illustrates cross sectional views taken along the linesin FIG. 12.

FIG. 15 illustrates a perspective view of an interior of the sprinklercompartment.

FIG. 16 illustrates a side perspective view of a pilot valve port.

FIG. 17 illustrates a side cross sectional view of a portion of thesprinkler of FIG. 1.

FIG. 18 illustrates a perspective view of the interior of the sprinklercompartment of FIGS. 4 and 5.

FIG. 19 illustrates a communication device for communicating with asensor and relaying data over a network.

DESCRIPTION OF EMBODIMENTS

Specific embodiments of the invention will now be described withreference to the accompanying drawings. This invention may, however, beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will be thorough and complete, and willfully convey the scope of the invention to those skilled in the art. Theterminology used in the detailed description of the embodimentsillustrated in the accompanying drawings is not intended to be limitingof the invention. In the drawings, like numbers refer to like elements.

One embodiment of the present invention is directed to a sprinkler 100having one or more internal compartments that are configured for storingvarious sprinkler components and allowing those components to beaccessed through a top of the sprinkler 100. This allows a user toeasily access and replace certain components within the sprinkler.

As seen best in FIGS. 1-3, the sprinkler 100 includes an outer housing102 and a riser portion 106. The riser portion 106 has a cylindricalshape and is fixed within a tubular passage 102A of the outer housing102. The tubular passage 102A is preferably offset from a center of thehousing 102 or asymmetrically positioned relative to the outer walls ofthe housing 102. As best seen in FIGS. 4 and 5, the offset arrangementof the passage 102A creates an internal compartment area 102D that canaccommodate larger components than would otherwise fit if the passage102A was centrally located in the same diameter housing 102. Forexample, a pilot valve 120, decoder 122, and water-resistant wireconnection tubes 124 can be located within the compartment area 102D.

The compartment area 102D can be divided into two or more distinctcompartments (e.g., 2, 3, 4, or 5 compartments) with dividing walls. Inthe present embodiment, wall 118 creates compartments 1026 and 102A,allowing components and wiring to be better separated from each other.

As seen in FIGS. 1-2, the sprinkler 100 preferably includes a cover 110having a similar size and offset aperture placement as housing 102. Thecover 110 can be a single component or can include multiple covercomponents (e.g., two) that can each be separately removed. Preferably,the cover 110 is secured in place via screws through apertures 112,however, other mechanisms of removably-securing the cover 110 to thehousing 102 are also possible (e.g., latches or detents).

Preferably, the cover 110 includes an angled or tapered ring 110A (seenbest in FIGS. 6 and 8), which fits against a reciprocally angled sidesurface 104B at the top of the riser housing 104. For example, the ring110A increases its diameter in the downward direction while the sidesurface 104B has an oppositely angled surface that increases itsdiameter in the upward direction. This engagement allows the cover 110to support the radial loads/stress in the riser housing 104 that mightotherwise require support by an integral flange on the riser housing104. The radial loads and stress in the riser housing 104 can result infatigue failure at the riser snap ring groove without adequate support(e.g., due to the pop-up impact of the riser 106 that is transmittedthrough the riser snap ring every time the sprinkler turns on). Hence,the surfaces 110A and 104B allow the cover 110 to be removed easily (itis not pressed onto a straight diameter) and does not have a flange,partial flange, higher strength material requirement, or an additionalpart which might reduce access to the compartment and increase the costto manufacture the sprinkler.

As seen in FIG. 4, the compartment area 102D may contain a pilot valve120, a decoder 122, and wire connectors 124, each of which can be easilyremoved from the top of the sprinkler 100, as seen in FIG. 5 (componentsremoved). However, as discussed elsewhere in this specification, othercomponents may also be located within the compartment area 102D.

The sprinkler 100 includes a valve assembly 126, seen best in FIGS. 6and 8, which is controlled by the decoder 122 and pilot valve 120. Thevalve assembly 126 includes a metering pin 134 which allows a smallamount of water to enter into valve chamber 133. As pressure builds inthe valve chamber 133, it forces down a valve seat 132, maintaining thevalve assembly 126 in a closed position.

The valve chamber 133 also includes a communication aperture 131 whichconnects to the communication tube 128. The tube 128 passes through therigid outer fin 114 and into a bottom portion of the housing 102. Asbest seen in FIGS. 7, 12, 13, 14, and 18, the tube 128 is connected to acheck valve 140 inside the compartment area 102D, which blocks flow ofwater through it until the first communication port 150 of the pilotvalve 120 is connected to it. Preferably, a top of the tube 128 ispositioned within the interior of the check valve 140.

The check valve 140 is maintained in a desired position in thecompartment area 102D by a lower, circular-shaped wall 157 that is fixedto or unitary with the floor of the area 102D. An upper cylindricalretainer 155 is sized to fit over and around the wall 157, trapping anenlarged base portion or flanged region 1446 of the check valve housing144. The base portion 144B is also positioned over the end of thecommunication tube 128 and is further sealed between the base portion144B and the base of the communication tube 128 by o-ring 146. In thisrespect, the check valve 140 can be removed and replaced by firstremoving the upper cylindrical retainer 155.

The valve mechanism within the check valve housing 144 comprises aspring 148 configured to push or bias a valve ball 142 upwards against anarrowed region 144A of the internal passage of the valve housing 144.The bottom surface of the narrowed region 144A forms a valve seatagainst which the valve ball 142 presses against, thereby stopping waterflow. When the first communication port 150 of the pilot valve 120 isinserted into the top opening of the housing 144, it pushes the ball 142downward, allowing water to flow through one or more side passages 152into the port 150 (e.g., 1, 2, 3, or 4 side passages). In this respect,water can freely flow into the pilot valve 120. The water flow throughthe pilot valve is further controlled by movement of a plunger against aseat within a central fluid passageway inside the pilot valve 120. Thisplunger can be moved by either an attached electronic solenoid 170 or byturning a manual actuator (not shown).

As seen in FIG. 11, the pilot valve 120 also includes a secondcommunication port 162 through which water pressure can be communicatedto the pilot valve 120 and relieved when the valve 126 is directed to beopened. As seen best in FIGS. 5, 9, 11, 15, 16, and 18, the secondcommunication port 162 connects to a receptacle 160 which is in fluidcommunication with an interior of the sprinkler body or riser housing104 (i.e., the passage in which the riser 106 moves upwards duringirrigation and downwards when not irrigating).

Preferably, an aperture or passage 130 is molded into the wall of theriser housing 104 (i.e., is part of the injection mold) to maintain arelatively smooth inner surface of the riser passage of the housing 104.Drilling or otherwise puncturing the wall of the housing 104 after theinterior passage is molded can result in small portions around theaperture 130 to protrude into the passage of housing 104, especially ifthe pilot valve 120 is configure to be screwed into this hole. Since theriser 106 includes a seal to prevent water leakage around the base ofthe riser 106 as it rises upwards during irrigation, any suchprotrusions or irregularities can damage this seal and/or can preventthe riser 106 from smoothly rising and falling.

The receptacle 160 preferably removably attaches to the outer surface ofthe wall of the riser housing 104. Specifically, the receptacle 160includes an upper flange 160D that fits within a downwardly-facing gapcreated by retaining member 163. Similarly, the bottom portion of thereceptacle 160 is sized to fit within a gap 161, thereby retaining thereceptacle against the outer wall of the riser housing 104. Preferably,the retaining member 163 and gap 161 are positioned to align the innerreceptacle passage 160B with the wall passage 130. To further maintainthe seal between the receptacle 160 and the outer wall of the riserhousing 104, the receptacle includes a recessed area around the end ofpassage 160B, which contains a resilient o-ring 158 that is compressedagainst the outer wall.

The inner receptacle passage 160B also connects to a cylindrical cavity160C which is open at its top. The second communication port 162 issized to fit within this cavity 160C, further connecting the passages130, 160B to the passages of the pilot valve 120. To enhance the ease ofconnection and maintain a proper seal, the end of the secondcommunication port 162 includes a tapered end 162A or nozzle and ano-ring 163.

It should be further noted that the check valve 140 and the receptacleare positioned within proximity of each other and preferably oriented inthe same or similar direction (e.g., upwards), as seen in FIGS. 5 and15. This spacing allows the first and second ports 150 and 162 of thepilot valve 120 to have similar spacing and an opposite orientation,allowing a user to easily remove the valve 120 (e.g., by simply pullingupwards on the valve 120) and easily installing a new valve 120 (e.g.,by simply pushing a new valve 120 downwards). Hence, the pilot valve 120can be quickly replaced from a top of the sprinkler 100.

The decoder 122, seen best in FIG. 4, communicates over a wire pair withan irrigation controller (e.g., such as a central irrigation controlleror a satellite irrigation controller) and thereby selectively appliespower to the solenoid 170 of the pilot valve 120, ultimately controllingirrigation of the valve. The wire pair enter the compartment area 102Dvia wire port 105 (seen best in FIG. 5) where they are connected to thewires of the decoder 122. Preferably, both sets of wires are eachconnected via an electrical wire nut 125, which is then further enclosedby a water-resistant tube 124 (see FIG. 4). The water-resistant tubes124 are filled with a thick, hydrophobic material, such as grease, so asto prevent water contact with any exposed metal and further preventcorrosion. Hence, two water-resistant tubes 124 can be used between thewire of the decoder 111 and the controller's wire pair.

As best seen in FIGS. 4 and 5, the compartment area 102D preferablyincludes several vertical ridges that are sized to retain the decoder122 when slid vertically down at a certain location within thecompartment area 102D. Hence, a user can slide a decoder 122 in or outof the compartment area 102D from the top of the sprinkler 100.

Turning to FIG. 17, the riser housing 104 is preferably injectionmolded. Additionally, the fin portion 114 of the riser housing 104preferably is molded around the communication tube 128, which ispreferably composed of a metal, such as stainless steel. In thisrespect, the communication tube 128 can maintain a bent shape and yetstill have substantially no gaps between its outer surface and the bodyof the riser housing 104. Preferably, the fin portion 114 also includesan open region 114A which exposes a portion of the communication tube128. This open region 114A may help prevent or limit unwanted shrinkageor warping that is sometimes inherent in the injection molding process.Additionally, the open region 114A allows the tube 128 to be directlysupported by the injection mold against the high pressures of moltenplastic during the injection molding process. Without such support, thetube 128 might otherwise bend or deform without providing substantiallyincreased support, such as a stronger material or thicker walled tube.In an alternate embodiment, the open region 114A may be relatively small(e.g., less than an inch) or may extend to just below the bottom ofouter housing 102. In another alternate embodiment, the communicationtube 128 is connected to the fin portion 114 after the injection moldingof the riser housing 104.

As seen in FIG. 18, the outer housing 102 is preferably connected to theriser passage housing 104 via a plurality of screws that pass throughseveral radially-extending apertures 104A. In one alternate embodiment,the outer housing 102 can be optionally added to an existing riser 106and riser housing 104, allowing users to upgrade existing sprinklers. Insuch an alternate embodiment, the apertures 104A may be part of anadd-on ring that connects to an existing riser housing or may includeother mechanical linking mechanisms, such as a clamp or latchingmechanism.

In one alternate embodiment shown in FIG. 19, the compartment of thesprinkler 100 may also contain a communication device 170 forcommunication with sensor 172. For example, the sensor may be a soilmoisture sensor (e.g., the sensors of U.S. Pat. Nos. 7,719,432;7,788,970; and 7,789,321; each of which are incorporated herein byreference); a weather station, or a rain sensor. The communicationdevice 170 may include a wireless transmitter to wirelessly communicatewith the sensor 172 and either wirelessly relay the data to network node174 (which is either a repeater or gateway) or can relay the data viathe decoder 122.

In one embodiment, a plurality of sprinklers, or even all sprinklers,may include their own communication device 170, forming a wireless meshcommunication network. This network may relay command signals from acentral irrigation controller, thereby eliminating the need for thetwo-wire decoder 122.

In another embodiment, the soil sensor 172 may be hard-wired to thesprinkler 100 and the communication device 170, allowing the sprinklerto power the sensor 172 and transmit its data.

In another example, the communication device 122 may wirelesslycommunicate with a remote control, allowing a user to send individualstart/stop commands to each sprinkler 100 (e.g., for testing purposes).The communication device 122 would either directly control the pilotvalve 120 or send control signals to the decoder 122.

In yet another example, device 170 may be any of the sensors describedin U.S. Pub. No. 20120043395, which is hereby incorporated by reference.For example, the sensors may include an acoustic feedback sensor, anaccelerometer, a gyroscope, a water sensor, a pressure sensor or aturbine. Each of these sensors can be configured to provide feedback asto whether the sprinkler's riser has “popped up” and is irrigatingproperly.

U.S. Pat. Nos. 7,631,813; 6,854,664; and 5,899,386 are herebyincorporated by reference.

Although the invention has been described in terms of particularembodiments and applications, one of ordinary skill in the art, in lightof this teaching, can generate additional embodiments and modificationswithout departing from the spirit of or exceeding the scope of theclaimed invention. Accordingly, it is to be understood that the drawingsand descriptions herein are proffered by way of example to facilitatecomprehension of the invention and should not be construed to limit thescope thereof.

What is claimed is:
 1. An irrigation sprinkler comprising: aninjection-molded riser housing having a top portion, a bottom portion,and a passage therethrough; a compartment located at said top portion ofsaid riser housing; a sprinkler riser located in said top portion ofsaid injection-molded riser and configured to vertically extend duringoperation; a metal communication tube having a first end positionedwithin said passage of said injection-molded riser; said communicationtube having a portion of its length that is surrounded by aninjection-molded portion of said injection-molded riser housing so as toprevent movement of said metal communication tube relative to saidinjection-molded riser housing; a main valve positioned in said bottomportion of said injection-molded riser and operatively connected to saidmetal communication tube; and, a pilot valve located in said compartmentand in communication with a second end of said metal communication tube.2. The irrigation sprinkler of claim 1, wherein said injection-moldedriser includes an outer fin extending radially away from an outer wallof said injection-molded riser; said outer fin surrounding a portion ofsaid metal communication tube.
 3. The irrigation sprinkler of claim 2,wherein said outer fin further comprises a lower portion contacting aninner side of said metal communication tube without contacting an outerside of said metal communication tube.
 4. The irrigation sprinkler ofclaim 1, wherein said metal communication tube has a curved shape andsubstantially no gaps between an outer surface of the metalcommunication tube and said injection-molded riser housing.
 5. Theirrigation sprinkler of claim 1, wherein said compartment is positionedentirely around said injection-molded riser housing.
 6. The irrigationsprinkler of claim 1, wherein said compartment further comprises a checkvalve and a pressure receptacle connected to said pilot valve.
 7. Theirrigation sprinkler of claim 6, wherein said pressure receptacle isfixed over an aperture through a side of said injection-molded riserhousing.
 8. The irrigation sprinkler of claim 7, wherein saidcompartment further comprises a two-wire decoder that is connected toactivate said pilot valve.
 9. An irrigation sprinkler comprising: aninjection-molded riser housing having a top portion, a bottom portion,and a passage therethrough; a compartment located at said top portion ofsaid riser housing; a sprinkler riser located in said top portion ofsaid injection-molded riser and configured to vertically extend duringoperation; a metal communication tube having a first end positionedwithin said passage of said injection-molded riser and having a curvedshape; and, a main valve positioned in said bottom portion of saidinjection-molded riser and operatively connected to said metalcommunication tube; wherein said injection-molded riser housing has beeninjection molded around a portion of a length of said metalcommunication tube so as to prevent movement of said metal communicationtube relative to said injection-molded riser housing.
 10. The irrigationsprinkler of claim 9, wherein a pilot valve located in said compartmentis in communication with a second end of said metal communication tube.11. The irrigation sprinkler of claim 10, wherein said injection-moldedriser includes an outer fin extending radially away from an outer wallof said injection-molded riser; said outer fin surrounding a portion ofsaid metal communication tube.
 12. The irrigation sprinkler of claim 11,wherein said outer fin further comprises a lower portion contacting aninner side of said metal communication tube without contacting an outerside of said metal communication tube.
 13. The irrigation sprinkler ofclaim 12, wherein said metal communication tube has substantially nogaps between an outer surface of the metal communication tube and saidinjection-molded riser housing.
 14. The irrigation sprinkler of claim13, wherein said compartment is positioned entirely around saidinjection-molded riser housing.
 15. An irrigation sprinkler comprising:a riser housing having a top portion, a bottom portion, and a passagetherethrough; a compartment located at said top portion of said riserhousing; a sprinkler riser located in said top portion of said riser andconfigured to vertically extend during operation; a metal communicationtube having a first end positioned within said passage of said riser;and, a main valve positioned in said bottom portion of saidinjection-molded riser and operatively connected to said metalcommunication tube; wherein said riser housing is injection moldedaround said metal communication tube so as to prevent movement of saidmetal communication tube relative to said riser housing and so as to bea unitary, non-removable portion of said riser housing.